After a request, here's my How-To for cleaning out the throttle body, EGR valve and the opening for the intake manifold. This is on my 2006 2.4 JTDm Lusso 200hp, I can't say if the later 210hp or 1.9 JTDms are the same - would welcome any input for this.
First, take off the engine cover.
If you're the kind of person that likes to use a triple thick condom, a femidom and an IUD as well just to be on the safe side, then if it makes you feel better you go ahead and take the battery +ve lead off too. In all honesty as long as the ignition is off, you don't need to, but each to their own...
From the photo above, undo the two hex head bolts ringed which hold the intake pipe on. You'll need a 5mm allen key or bit to do this.
Lift it clear. If you can, follow this pipe toward the front of the engine and remove the clip holding the solid pipe to the rubber hose. Lift the solid pipe clear to give you more manoeuvring room - I didn't as I'm an adventurous bugger and didn't like the look of the access and the clip!
Edit: Several good folk have reported back that the O-ring on the intake pipe has stretched, so it may well pay you to have a new one ready to fit. They aren't expensive and can avert a lot of hassle and creative language when refitting.
From the photo above, undo the two allen bolts ringed, and the one below shown by the arrow. Again, a 5mm allen key / bit needed. This will release the throttle body. Be careful not to drop the gasket as you'll have slim chance of finding it again....!
The bracket and heat shield arrowed above will need to be taken off next. Use a 10mm socket.
Then first loosen the two vertical 13mm bolts shown below before tackling the horizontal ones. When you take these off, the oval slip ring holding the EGR pipe to the EGR valve will drop, worry not as it just slides down the pipe an inch or so and isn't a problem. Do make sure you fish the oval gasket out between pipe and valve though.
Then loosen the 4 horizontal 10mm bolts holding the EGR valve to the intake manifold. Again, make sure you recover the gasket between the two parts.
For the left hand side bolts, a deep 10mm socket is handy.
Now on to the EGR valve. Clean out all the openings as best you can. If you want to remove the actuator, you will need a TX25 Torx bit. Mark up the orientation if you're doing this so you get it back on the right way.
Try blowing through it to see if it seals properly when closed. You will get the full boot-polish-on-the-telescope effect around your mush, so do be prepared!
Mine didn't seal, not by a long chalk.....
You can move the valve by hand and clean the seats if required. They can be made to seal fully with a little perseverance.
Now refit the throttle body, EGR and pipework. Go slowly and check you have tightened all the bolts, refitted the clips and routed the cables correctly.
Remember there is a nut between the 10mm bolts and the heatshield on the EGR, also another nut between the heatshield and cable bracket.
Oh, and try not to drop any bolts or gaskets - there isn't a lot of room down below and things can be a right pain in the arse to find and recover!
Now reward youself with a nice hot bath as you will be bloody caked with black crap. Ensure beers are pre-chilled too (or room temp for us real, Real Ale men ), these are essential for post job celebration. You've just saved yourself about £100 worth of garage fees, so enjoy!
After completing this, the idle became as smooth as silk on mine, no fluctuations or coughing.
Just used part of your guide to sort out the problems I was having. I put the gasket mentioned above in with raised area towards EGR.
Had to change my EGR as the clean-up wasnt enough. All is working great, DPF was at 114% but idled her to 90°C in garage and went for a drive and she regen'd nicely during the trip. Haven't rechecked %age with FIatECUScan but she is nice and smooth running again.
I did notice that my intake wasn't coked up at all but, was 'oily'. Don't know why, maybe regular Wynns treatment or another problem to be found at a later date.
All in all, can't recommend this guide as a sticky highly enough !
That is kinda like how mine was, more of an oily film over the throttle than a sooty one. Mine hadn't dripped out onto the connector but, I would agree with the theory that its from the breather pipe.
I have to wonder if this is intended or indication of a different kind of issue to the coking up one.
Just did mine. Wasnt too bad, but was gunked up, especially around the butterfly valve itself, so a good can of carb cleaner sorted it out and got it all shiny again!
2 "gotchas" I found...
1) The Sealing riing that comes off the intake pipe is prone to stretch and I needed to replace mine as a result. Was only £6.37 from the local main dealer and they usualloy have then in stock as its known to stretch on removal.
2) The metal gasket on the manifold side had paint flaking off once I cleaned it. I spoke to teh main dealer who said its fine, just clean it off, so i picked off and sanded smooth the flaking paint areas and refitted.
All works fine.
Cheers for the guide Pete.
Of course, the real issue here is the amount of oil being stuffed through the intake, which would be solved with a catch can. Add to that a water/meth injection system and the intake would be sparkly clean in a couple of thousand miles!